Packaging process and related working station

ABSTRACT

A packaging process includes the steps of receiving distinct clusters of products, orienting layered groups, moving the groups closer together, and inserting the bundle within a respective package. With the receiving step, the sum of the products of the clusters is equal to the number of products that can be accommodated in a layer of the final package. The products are mutually stacked so as to constitute respective layered groups that constitute a bundle. The layered groups that constitute a bundle are oriented according to the correct alignment required for its entry into the final package. The layered groups that constitute a bundle are moved closer to mutually contact the last product of one group with the first product of the contiguous group. Finally, the bundle constituted by the compacted layered groups, is inserted within a respective package.

TECHNICAL FIELD

The present disclosure relates to a packaging process and to a related working station particularly for plate-like products.

In particular, the packaging process and the corresponding working station according to the disclosure are particularly adapted for tablet-shaped chewing gums.

BACKGROUND

The packaging system for tablet chewing gums is constituted by a series of consecutive stations: a wrapping machine intended to cover individually, with specific sheets, each tablet, a feeder assembly intended to arrange the wrapped tablets according to consecutive clusters, a stacking assembly intended to create the bundle to be packed and a casing machine suitable to insert the bundle in a specific wrap.

The wrapping machine transfers the wrapped tablets to the feed on one or two distinct channels; the feed, also provided with two channels, has the task of transferring the products in transport trays that lead to the stacking assembly.

Downstream of the stacker, the tablets arranged tidily in bundles are inserted in turn in the wrap by the casing machine.

The format of the bundle to be inserted in the wrap comprises a plurality of tablets: particularly, a particular interest is found for bundles constituted by seven tablets in series arranged on three stacked layers.

The possibility of having to provide bundles constituted by a different (greater or smaller) number of tablets with respect to what is indicated in the preceding paragraph by way of example is not excluded.

Unfortunately, however, the tablets have considerable dimensional tolerances that compromise their correct arrangement in the transport trays.

The dimensional tolerance of the chewing gum tablets is on the order of magnitude of approximately ±4% (although cases are known in which it is even greater); this means that products with maximum dimensional differences equal to 8%, thus particularly conspicuous, might face each other.

When stacking various bundles of tablets, one encounters an extremely onerous condition, since there will be the risk that a tablet might rotate and “fall” into the space that is present between two adjacent tablets of the lower layer: in fact, two adjacent tablets might find themselves at a mutual distance (the maximum tolerance preset on the length of the bundle) that might be greater than the thickness of the tablets themselves; this mutual distance, therefore, is suitable to accommodate a tablet arranged transversely with respect to the others.

If this condition of incorrect arrangement occurs, the system can no longer proceed effectively up to casing, because it will be prevented from the transverse arrangement of the tablet that has “fallen” into the channel between two contiguous tablets of the lower layer.

This problem is even more evident as the dimensional tolerance provided for each individual tablet increases and as the bundle to be layered increases in size (and thus is constituted by a large number of tablets).

In order to prevent these problems, one might think to perform stacking very slowly and by retaining each individual tablet: this would cause a considerable reduction of the efficiency of the system and the need to have grip means dedicated to each individual type of tablet, with a consequent increase in costs and complexity upon any format change.

SUMMARY

The aim of the present disclosure is to solve the problems mentioned above, by proposing a packaging process that allows high efficiency and productivity, avoiding incorrect arrangements of the products.

Within this aim, the disclosure proposes a packaging process that is simple and can be performed by means of working stations that are scarcely subject to failures and malfunctions.

The disclosure further provides a working station that allows to handle the products quickly and safely, providing stable stratifications.

The present disclosure also provides a packaging process and a corresponding working station that have low costs, are relatively easy to provide and safe in use.

These benefits are achieved by providing a packaging process, comprising the steps of

-   -   receiving distinct clusters of products, the sum of the products         of said clusters being equal to the number of products that can         be accommodated in a layer of the final package, and mutually         stacking them so as to constitute respective layered groups that         constitute a bundle;     -   orienting the layered groups that constitute a bundle according         to the correct alignment required for its entry into the final         package;     -   moving mutually closer the layered groups that constitute a         bundle up to mutual contact of the last product of one group         with the first product of the contiguous group;     -   inserting the bundle constituted by the compacted layered groups         within a respective package.

These benefits are also achieved by providing a corresponding working station for stacking products of the type comprising at least one supply line of products and at least one exit channel for stacked products, characterized in that said at least one supply line comprises receptacles for clusters of products mutually arranged side by side and said at least one exit channel comprises containment recesses for groups of products that are mutually arranged side by side and stacked, at least one pusher facing the lateral edge of said supply line, the end of said pusher being movable from a passive configuration for alignment with said lateral edge of said supply line to an active configuration for alignment with the lateral edge of said exit channel for the transfer of the products accommodated in the receptacles of said supply line to the recesses of said exit channel according to successive stacked layers.

BRIEF DESCRIPTION OF THE DRAWINGS

Further characteristics and advantages of the disclosure will become better apparent from the description of a preferred but not exclusive embodiment of the packaging process and the related working station according to the disclosure, illustrated by way of non-limiting example in the accompanying drawings, wherein:

FIG. 1 is a perspective view of the functional diagram of the packaging process according to the disclosure;

FIG. 2 is a perspective view of the functional diagram of the first step of the packaging process according to the disclosure;

FIG. 3 is a perspective view of the functional diagram of the second step of the packaging process according to the disclosure;

FIG. 4 is a perspective view of the functional diagram of the third step of the packaging process according to the disclosure;

FIG. 5 is a perspective view of the functional diagram of the fourth step of the packaging process according to the disclosure;

FIG. 6 is a perspective view of the industrial apparatus comprising the working station according to the disclosure;

FIG. 7 is a perspective view of the working station according to the disclosure;

FIG. 8 is a perspective enlarged-scale view of the working station according to the disclosure;

FIG. 9 is a perspective view, taken along a different orientation, of a portion of the working station according to the disclosure; and

FIG. 10 is a perspective view of the functional diagram of the packaging process according to the disclosure, comprising the representation of the working station according to the disclosure.

DETAILED DESCRIPTION OF THE DRAWINGS

With reference to the figures, a packaging process is generally designated by the reference numeral 1 and a corresponding working station, intended to pack specifically tablet-like shaped products A, is designated by the reference numeral 2.

The packaging process 1 according to the disclosure provides for a sequence of consecutive steps.

A first step 1 a provides for receiving distinct clusters 3, 4 of products A.

It is specified that the sum of the products A of said clusters is equal to the number of products A that can be accommodated in a layer of the final package 5, and mutually stacking them so as to constitute respective layered groups 6, 7 that constitute a bundle 8.

Within the scope of a second step 1 b, it is necessary to orient the layered groups 6, 7 that constitute a bundle 8 according to the correct alignment required for the entry of said bundle 8 in the final package 5.

In a third step 1 c, the layered groups 6, 7 are moved mutually closer up to mutual contact of the last product A of one group 6 with the first one of the contiguous group 7 so that the two groups 6, 7 are joined, constituting a bundle 8 in which the products follow each other without discontinuities.

In a fourth step 1 d, it is necessary to insert the bundle 8 constituted by the compacted layered groups 6, 7 into a respective package 5.

Before the third step 1 c there is the possibility to transfer the products A, during a specific step 1 e, on a specific supply line of the station intended to insert the bundle 8 in the package 5 (usually called casing machine).

It should be noted that the first receiving step 1 a entails that the products A are individually wrapped (since they arrive from a respective station arranged upstream and designed for the individual wrapping of the products A) and oriented uniformly, as well as already divided into clusters 3 and 4.

According to a particular constructive solution of unquestionable practical interest, the clusters 3 and 4 of products A are two in number: a first cluster 3 is constituted by at least two products A and a second cluster 4 is constituted by at least three products A.

If the bundle 8 to be provided is constituted by 7 products A (a particularly interesting hypothesis in relation to the packages 5 of chewing gums), the first cluster 3 is constituted by three products A, while the second cluster 4 is constituted by four products.

In general terms, anyway, the clusters 3 and 4 might also be in a number greater than two and, at the same time, each cluster 3 or 4 might be constituted by any number of products A.

It is also specified that within the scope of the process 1 according to the disclosure, each layered group 6, 7 comprises at least two layers of clusters 3, 4 of stacked products A.

Preferably, with particular reference to a constructive solution of unquestionable practical interest, the layers of stacked products A in each group 6, 7 are three in number.

Moreover, it is convenient to specify that the second step 1 b of orientation of the groups 6, 7 provides for turning them over with a total rotation through 180°.

This overturning is necessary in order to arrange the products A so that their wrapping is oriented correctly with respect to the package 5 within which they must be inserted, in order to prevent any flaps of the wrapping from causing contrast with the package 5 and/or prevent the appearance of the finished product (bundle of layered products A inserted into the package 5) has an unpleasant appearance or an appearance that does not conform to the standards imposed by the manufacturer.

It is also noted that, with particular reference to a first possible embodiment, the third step 1 c of mutual approach, compaction, of layered groups 6, 7 that constitute a bundle 8 entails the forced slowdown of the group 6 arranged downstream until the limiting edge of the group 7 arranged upstream rests thereon.

In practice, by slowing down the group 6 (arranged downstream) that is entrained in motion by the same line on which the group 7 (arranged upstream) is traveling, the group 6 is reached by the group 7 with consequent compaction to form a single bundle 8 constituted by tablet-shaped products uninterruptedly arranged side by side and stacked on multiple layers.

Preferably, according to a further embodiment, the approach of the group 6 to the group 7 is provided by forcing the groups 6 and 7 to trace converging trajectories during their transfer.

More specifically, the third step of mutual approach, compaction, of layered groups 6, 7 is obtained by means of a succession of consecutive transfers on different conveyance means provided with contiguous receptacles separated by a progressively thinner wall.

The present disclosure relates also to a working station 2 for stacking products A that comprises at least one supply line 9 for supplying products A and at least one exit channel 10 for stacked products A.

It is specified moreover that the at least one supply line 9 comprises receptacles 11 and 12 for clusters 3 and 4 of products A arranged mutually side by side.

The at least one exit channel 10 comprises instead containment recesses 13 and 14 for groups 6 and 7 of products A that are arranged mutually side by side and stacked.

The station 2 comprises, moreover, at least one pusher 15 that faces the lateral edge of the supply line 9.

The end of the pusher 15 is movable from a passive configuration for alignment with the lateral edge of the supply line 9 to an active configuration for alignment with the lateral edge of the exit channel 10.

The transfer of the end of the pusher 15 from the passive configuration to the active configuration allows the transfer of the products A accommodated in the receptacles 11 and 12 of the supply line 9 to the recesses 13 and 14 of the exit channel 10 according to successive stacked layers.

According to a particular constructive solution of particular interest in application, the station 2 comprises contrast means 16, which are associated functionally with a respective actuator 17: the contrast means 16 constitute a translating movable base for the recesses 13 and 14 during the step of insertion and stacking of the products A therein.

The channel 10 comprises a plurality of consecutive carriages 18 provided with recesses 13 and 14 delimited by side walls 19 and mutually divided by at least one partition 20.

The side walls 19 and the partition 20 have at least the same height as the groups 6 and 7 of products A that are layered and stacked and are intended to be accommodated in the recesses 13 and 14.

This dimensional solution has the purpose of avoiding any escape of stacked products within the recesses 13 and 14.

The carriages 18 comprise contoured delimiting plates 21: each plate 21 comprises in turn respective teeth that constitute the side walls 19 and respective columns that constitute the partition 20.

The contrast means 16 are thus able to translate between the contoured delimiting plates 21 by way of the action of a respective actuator 17.

More specifically, it is clarified that the contrast means 16 comprise bands that are parallel to the bottom of carriages 18.

At least one band is interposed between the plates 21 and at least one further band is external to the plates.

Such bands are integral with respective stems 22 associated with an actuator 17 for varying the height of the bands.

The height variation occurs between a configuration of substantial coplanarity thereof with the bottom of the carriages 18 and a configuration that is raised by a height that is substantially similar to the thickness of the groups 6, 7 of stacked products A.

With respect to these extreme configurations there are also stable intermediate configurations that correspond to a configuration that is raised by a height equal to the thickness of a product A, to a configuration that is raised by a height equal to the thickness of two products A, and further optional raised configurations arranged at a height defined by an incremental pitch with respect to the previous one that corresponds to the thickness of a further product A stacked on those already stacked, until the intended thickness for the groups 6 and 7 is reached.

Analyzing in greater depth the station 2, it can be noted that downstream of the contrast means 16 (provided with the bands supported by the stems 22) there are pressers 23 (functionally associated with a respective actuation element 24) that have the purpose of arranging themselves proximate (even up to contact and optional compression) to the stacked products A in order to ensure the stability of their configuration.

The step for transferring the clusters 3 and 4 from the receptacles 11 and 12 of the supply line 9 to the recesses 13 and 14 of the exit channel 10 must be performed while ensuring that the arrangement of the products A is correct.

For this reason, there is a further guiding apparatus 25 that comprises columns 26 (provided with grooves that allow the passage of the carriages 18).

The columns 26, on their face directed toward the supply line 9, comprise beveled (or generically inclined) surfaces that facilitate the entry of the clusters 3 and 4 into the recesses 13 and 14; the side walls of the columns 26 subsequently guiding the stroke of the clusters 3 and 4 up to their correct arrangement in the recesses 13 and 14 (so as to constitute the groups 6 and 7).

The guiding apparatus 25 also can move (by rising when the carriage 18 that contains the groups 6 and 7 must exit from the station 2 and by lowering during the operations for stacking of the clusters 3 and 4 to constitute the groups 6 and 7): the apparatus 25 is controlled by a respective handling element 27.

It is specified that the actuator 17, the actuation element 24 and the handling element 27 might be provided by using controlled electric motors on which respective mechanisms of the rod-and-crank type are keyed. The use of different constructive solutions is not excluded.

Operation of the station 2 is intuitive: the clusters 3 and 4 of products A arrive from the line 9 inside the receptacles 11 and 12 to the station up to the condition of alignment with the pusher 15, which translates them laterally until they are accommodated within the recesses 13 and 14 of the channel 10.

When the recesses 13 and 14 are empty, the products A, during this translation, rest against the base constituted by the bands of the contrast means 16.

The contrast means 16 descend by an incremental pitch equal to the thickness of a single product A, by way of the action of the actuator 17.

In this step, the pressers 23 are arranged proximate (even up to contact and optional compression) to the stacked products A in order to ensure the stability of their configuration.

Again, other clusters 3 and 4 of products A are aligned with the pusher 15 that translates them in the recesses 12 and 13, making sure that they rest against the products A inserted previously, providing a first stacking.

It is specified that upon the arrival of the groups 3 and 4 by action of the pusher 15 the pressers rise, allowing the entry of the groups 3 and 4 superimposed on those already inserted.

This sequence is repeated until the number of layers of products A provided by the package 5 within which the bundle 8 must be inserted is provided.

It is useful to stress that the entry of the clusters 3 and 4 in the recesses 13 and 14 is guided correctly and completely by the guiding apparatus 25, in order to ensure that the products A maintain mutual alignment during their transfer.

Once the groups 6 and 7 have been provided, the carriage 18 moves downstream in order to allow the filling of the recesses 13 and 14 with groups 6 and 7 of products of the carriage that is upstream.

During the movement of the carriage 18, the guiding apparatus 25 is raised, while the pressers 23 remain in the lowered configuration (i.e., proximate to the upper surface of the groups 6 and 7) in order to ensure the stability of their configuration.

Advantageously, the present disclosure solves the problems described earlier, by devising a packaging process 1 that allows high efficiency and productivity, avoiding incorrect arrangements of the products A.

In fact, the sequence of operations is such as to ensure that the clusters 3 and 4 of products A and the groups 6 and 7 of layered products A are kept separated and tidily arranged (by way of the presence of the receptacles 11 and 12 and of the recesses 13 and 14).

Positively, the packaging process 1 is particularity simple and, moreover, can be performed by means of working stations that are scarcely subject to failures and malfunctions.

Conveniently, the working station 2 according to the disclosure allows to handle the products A in a quick and safe manner, providing stable stratifications, this in relation to the transfer, by means of the pusher 15, of the clusters 3 and 4 of products A from the receptacles 11 and 12 to the recesses 13 and 14 in order to constitute the groups 6 and 7 of layered products A (stratification/stacking obtained by arranging clusters 3 and 4 above other clusters 3 and 4 already inserted in the recesses 13 and 14).

Efficiently, the packaging process 1 and the related working station 2 entail low manufacturing costs and are therefore relatively easy to provide in practice and are safe in use.

The disclosure thus conceived is susceptible of numerous modifications and variations, all of which are within the scope of the appended claims; all the details may further be replaced with other technically equivalent elements.

In the examples of embodiment shown, individual characteristics, given in relation to specific examples, may actually be interchanged with other different characteristics that exist in other examples of embodiment.

In practice, the materials used, as well as the dimensions, may be any according to requirements and to the state of the art.

The disclosures in Italian Patent Application No. BO2014A000132 from which this application claims priority are incorporated herein by reference. 

1-12. (canceled)
 13. A packaging process, comprising the steps of receiving distinct clusters of products, a sum of the products of said clusters being equal to a number of products that can be accommodated in a layer of a final package, and mutually stacking the products so as to constitute respective layered groups that constitute a bundle; orienting the layered groups that constitute a bundle according to a correct alignment required for its entry into the final package; moving mutually closer the layered groups that constitute a bundle such that the last product of one group mutually contacts the first product of the contiguous group; and inserting the bundle constituted by the compacted layered groups within a respective package.
 14. The process according to claim 13, wherein the first step of receiving distinct clusters of products provides for the products to be wrapped individually and oriented uniformly.
 15. The process according to claim 13, wherein the clusters of products are two in number, a first cluster constituted by at least two products and a second cluster constituted by at least three products.
 16. The process according to claim 15, wherein the first cluster is constituted by three products and the second cluster is constituted by four products.
 17. The process according to claim 13, wherein each layered group comprises at least two layers of clusters of stacked products.
 18. The process according to claim 13, wherein the second step of orienting the layered groups provides for turning the groups over with a total rotation of 180°.
 19. The process according to claim 13, wherein the third step of moving mutually closer, compaction of layered groups that constitute a bundle entails a succession of consecutive transfers on different conveyance means provided with contiguous receptacles separated by a progressively thinner wall.
 20. A working station for stacking products of, the working station comprising: at least one supply line for supplying products, and at least one exit channel for stacked products, wherein said at least one supply line comprises a plurality of receptacles for clusters of products arranged mutually side by side, and said at least one exit channel comprises a plurality of containment recesses for groups of products that are arranged mutually side by side and stacked, at least one pusher facing the lateral edge of said supply line, the end of said pusher being movable from a passive configuration for alignment with said lateral edge of said supply line to an active configuration for alignment with the lateral edge of said exit channel for the transfer of the products accommodated in the receptacles of said supply line to the recesses of said exit channel according to stacked successive layers.
 21. The working station according to claim 20 further comprising contrast means functionally associated with a respective actuator, contrast means constituting a translating movable base for said recesses.
 22. The working station according to claim 20, wherein said channel comprises a plurality of consecutive carriages provided with recesses delimited by side walls and mutually divided by at least one separation partition, said side walls and said partition having at least the same height as the groups of products that are layered and stacked and configured to be accommodated in said recesses.
 23. The working station according to claim 21, wherein said carriages comprise contoured delimiting plates, each plate comprising respective teeth that constitute said side walls and respective columns that constitute said partition, said contrast means being able to translate between said contoured delimiting plates by way of the action of a respective actuator.
 24. The working station according to claim 21, wherein said contrast means comprise bands that are parallel to the bottom of said carriages, at least one band being interposed between said plates and at least one band being external thereto, said bands being integral with respective stems associated with an actuator for varying the height of said bands, between a configuration of substantial coplanarity with the bottom of said carriages and a configuration that is raised by a height that is substantially similar to the thickness of said groups of superimposed products. 